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These are the user uploaded subtitles that are being translated: 1 00:00:01,469 --> 00:00:02,534 Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS," 2 00:00:02,536 --> 00:00:04,762 THE ALL-NEW JAGUAR XF, 3 00:00:04,764 --> 00:00:08,290 A LUXURY SEDAN THAT PROWLS THE HIGHWAYS IN LAVISH STYLE. 4 00:00:08,292 --> 00:00:11,227 -- Captions by VITAC -- www.vitac.com 5 00:00:11,229 --> 00:00:14,255 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 6 00:00:23,584 --> 00:00:27,444 JAGUAR HAS BEEN BUILDING CARS FOR MORE THAN 80 YEARS. 7 00:00:27,446 --> 00:00:29,438 IN THE 1950s AND '60s, 8 00:00:29,440 --> 00:00:31,573 THEY ESTABLISHED AN ELEGANT PROFILE 9 00:00:31,575 --> 00:00:33,099 FOR THEIR SEDANS, 10 00:00:33,101 --> 00:00:37,129 WHICH BECAME THE CARMAKER'S SIGNATURE STYLE FOR DECADES. 11 00:00:37,131 --> 00:00:40,800 IN 2007, THE COMPANY LAUNCHED THE XF, 12 00:00:40,802 --> 00:00:45,455 CREATING A COMPLETELY NEW LOOK FOR THE 21st CENTURY. 13 00:00:45,457 --> 00:00:49,058 THE SECOND-GENERATION XF, REVEALED IN 2015, 14 00:00:49,060 --> 00:00:53,120 IS A COMPLETELY CLEAN-SHEET DESIGN. 15 00:00:53,122 --> 00:00:56,215 THE DIFFERENCES BEGIN WITH AN ALL-NEW ARCHITECTURE, 16 00:00:56,217 --> 00:01:01,738 MADE ALMOST ENTIRELY OF BONDED AND RIVETED ALUMINUM. 17 00:01:01,740 --> 00:01:06,068 THE RESULT IS A LIGHTER, MORE RIGID CAR. 18 00:01:06,070 --> 00:01:07,803 IMPROVED PERFORMANCE ALSO COMES 19 00:01:07,805 --> 00:01:12,033 FROM A RANGE OF JAGUAR'S NEW DIESEL INGENIUM ENGINES. 20 00:01:12,035 --> 00:01:14,494 INGENIUM IS A FAMILY OF COMPACT, 21 00:01:14,496 --> 00:01:17,697 LIGHTWEIGHT, LOW-EMISSION, TURBOCHARGED POWER PLANTS 22 00:01:17,699 --> 00:01:21,827 BUILT AT JAGUAR LAND ROVER'S NEW ENGINE MANUFACTURING CENTER. 23 00:01:27,117 --> 00:01:28,850 THE BODY OF THE XF STARTS 24 00:01:28,852 --> 00:01:33,380 WITH NEARLY 20,000 POUNDS OF COILED SHEET METAL. 25 00:01:33,382 --> 00:01:35,774 JAGUAR USES A COMBINATION OF ALUMINUM 26 00:01:35,776 --> 00:01:38,836 AND STEEL TO CREATE THE XF BODY. 27 00:01:38,838 --> 00:01:40,971 WHILE ALUMINUM SAVES WEIGHT, 28 00:01:40,973 --> 00:01:45,935 JUDICIOUS USE OF STEEL IMPROVES WEIGHT DISTRIBUTION. 29 00:01:45,937 --> 00:01:48,263 ONCE THE METAL IS CUT INTO THE REQUIRED SHAPES, 30 00:01:48,265 --> 00:01:50,791 AN AUTOMATED SYSTEM USES SUCTION CUPS 31 00:01:50,793 --> 00:01:54,787 TO DESTACK THEM. 32 00:01:54,789 --> 00:01:56,722 THE SYSTEM THEN LOADS THE SHAPES, 33 00:01:56,724 --> 00:01:59,283 KNOWN AS BLANKS, INTO A MASSIVE DIE. 34 00:01:59,285 --> 00:02:00,551 THE UPPER SECTION OF THE DIE 35 00:02:00,553 --> 00:02:02,419 DESCENDS AND COLD-PRESSES 36 00:02:02,421 --> 00:02:05,481 THE METAL TO THE DESIRED THREE-DIMENSIONAL FORM. 37 00:02:05,483 --> 00:02:07,341 THE 110,000-POUND DIE 38 00:02:07,343 --> 00:02:09,644 CAN PRESS 20 BLANKS PER MINUTE. 39 00:02:15,368 --> 00:02:19,304 THE SECOND OPERATION PERFORMS THREE FUNCTIONS SIMULTANEOUSLY. 40 00:02:19,306 --> 00:02:23,592 IT PIERCES, FOLDS AND TRIMS THE PANEL TO CREATE THE OPENINGS 41 00:02:23,594 --> 00:02:25,760 AND FLANGES NECESSARY FOR THE PART, 42 00:02:25,762 --> 00:02:27,855 WHICH IS A STEEL INNER DOOR PANEL. 43 00:02:31,427 --> 00:02:33,885 THE PRESS LINE USES LARGE SERVOMOTORS 44 00:02:33,887 --> 00:02:38,316 TO PROCESS UP TO 1,200 BLANKS PER HOUR. 45 00:02:38,318 --> 00:02:41,177 THIS CUTTING-EDGE TECHNOLOGY CAN PRODUCE A PANEL 46 00:02:41,179 --> 00:02:42,711 EVERY THREE SECONDS, 47 00:02:42,713 --> 00:02:45,874 MAKING IT THE FASTED STAMPING LINE IN THE WORLD. 48 00:02:48,436 --> 00:02:51,304 THE BODY SHOP WHERE THE XF BEGINS TO TAKE SHAPE 49 00:02:51,306 --> 00:02:55,200 IS THE SIZE OF 12 FOOTBALL FIELDS. 50 00:02:55,202 --> 00:02:59,130 DESPITE THAT, THE SHOP REQUIRES ONLY 57 EMPLOYEES 51 00:02:59,132 --> 00:03:01,056 BECAUSE THE LINE IS LARGELY MANNED 52 00:03:01,058 --> 00:03:02,925 BY ROBOTS LIKE THIS ONE, 53 00:03:02,927 --> 00:03:04,952 WHICH ASSEMBLES THE UNDERFLOOR. 54 00:03:07,123 --> 00:03:12,418 BODY-SIDE INNERS GO ON NEXT AS THE UNDERFLOOR PROCEEDS. 55 00:03:12,420 --> 00:03:15,480 ROBOTS WILL JOIN THE METAL COMPONENTS BY SPOT-WELDING, 56 00:03:15,482 --> 00:03:19,009 GLUING, AND RIVETING THEM TOGETHER. 57 00:03:19,011 --> 00:03:21,403 GLUING AND RIVETING MAKES FOR A POWERFUL, 58 00:03:21,405 --> 00:03:23,372 TORSIONALLY RIGID JOINT. 59 00:03:25,568 --> 00:03:28,994 IT'S ALSO NECESSARY IN SOME PLACES BECAUSE, AS NOTED, 60 00:03:28,996 --> 00:03:31,630 WHILE THE XF BODY IS MOSTLY ALUMINUM, 61 00:03:31,632 --> 00:03:34,692 SOME OF THE COMPONENTS ARE MADE OF STEEL. 62 00:03:34,694 --> 00:03:36,894 THE TWO METALS CANNOT BE WELDED TOGETHER 63 00:03:36,896 --> 00:03:39,489 AND SO MUST BE JOINED BY OTHER MEANS. 64 00:03:44,321 --> 00:03:47,514 ROBOTS HAVE INSTALLED THE REAR EXTERIOR PANELING. 65 00:03:47,516 --> 00:03:50,242 SPECIAL NOISE-REDUCING PADS PLACED BETWEEN THE INNER 66 00:03:50,244 --> 00:03:52,244 AND OUTER LAYERS WILL LATER EXPAND 67 00:03:52,246 --> 00:03:54,505 IN THE PAINT-SHOP OVENS. 68 00:04:02,725 --> 00:04:05,017 Narrator: IT'S HARD TO BELIEVE SUCH A SLEEK OBJECT 69 00:04:05,019 --> 00:04:06,686 WAS EVER A BUNCH OF METAL COMPONENTS 70 00:04:06,688 --> 00:04:10,248 WAITING TO BE PUT TOGETHER. 71 00:04:10,250 --> 00:04:11,648 IT TAKES A LOT OF PLANNING 72 00:04:11,650 --> 00:04:15,145 AND WORK TO MAKE A JAGUAR XF LOOK SO GOOD. 73 00:04:18,708 --> 00:04:21,168 A LIFT ASSIST HOLDS THE REAR RIGHT-HAND DOOR 74 00:04:21,170 --> 00:04:22,302 AT THE CORRECT ANGLE 75 00:04:22,304 --> 00:04:25,631 AS A TECHNICIAN GUIDES IT INTO POSITION. 76 00:04:25,633 --> 00:04:32,454 HE USES A HANDHELD DRIVER TO CONNECT THE HINGES. 77 00:04:32,456 --> 00:04:34,456 TEAM MEMBERS GUIDE THE HOOD INTO PLACE 78 00:04:34,458 --> 00:04:37,051 AS THE LIFT ASSIST RESPONDS TO THE MOVEMENT 79 00:04:37,053 --> 00:04:40,913 AND PRESSURE OF THEIR HANDS. 80 00:04:40,915 --> 00:04:42,782 THEY HAND-START THE FASTENER BOLTS 81 00:04:42,784 --> 00:04:44,742 TO AVOID CROSS-THREADING THEM. 82 00:04:44,744 --> 00:04:47,479 THE DRIVERS THEY USE ARE DIGITALLY CONNECTED TO 83 00:04:47,481 --> 00:04:48,872 A WIRELESS NETWORK, 84 00:04:48,874 --> 00:04:51,875 WHICH PROVIDES THE NECESSARY INFORMATION ABOUT TORQUE 85 00:04:51,877 --> 00:04:53,836 WHILE RECORDING THE OPERATION. 86 00:04:57,800 --> 00:05:00,960 A TECHNICIAN MANUALLY INSTALLS THE RIGHT FRONT FENDER. 87 00:05:00,962 --> 00:05:02,628 HE HAND-STARTS THE FASTENERS 88 00:05:02,630 --> 00:05:04,897 BECAUSE HE MUST VERIFY A FLUSH FIT 89 00:05:04,899 --> 00:05:06,424 AND CORRECT CAP DISTANCES 90 00:05:06,426 --> 00:05:08,760 BEFORE TORQUING THEM DOWN COMPLETELY. 91 00:05:10,956 --> 00:05:12,956 AT THE HIGHLIGHT INSPECTION STATION, 92 00:05:12,958 --> 00:05:15,617 HIGHLY TRAINED TECHNICIANS WIPE A SPECIAL TEMPORARY 93 00:05:15,619 --> 00:05:18,511 COATING ONTO THE CAR'S SURFACE. 94 00:05:18,513 --> 00:05:20,380 THE REFLECTIVITY OF THE COATING HELPS THEM 95 00:05:20,382 --> 00:05:24,443 IDENTIFY ANY IMPERFECTIONS IN THE METAL. 96 00:05:24,445 --> 00:05:26,103 IN ADDITION, THE VERTICAL STRIP 97 00:05:26,105 --> 00:05:28,506 LIGHTING CREATES A REFLECTIVE PATTERN. 98 00:05:28,508 --> 00:05:30,632 ANY DEVIATIONS IN THE REFLECTIVE PATTERN 99 00:05:30,634 --> 00:05:32,301 COULD INDICATE A FLAW. 100 00:05:36,132 --> 00:05:38,257 THERE ARE TWO REWORK STATIONS, 101 00:05:38,259 --> 00:05:41,727 ONE FOR THE STEEL SECTIONS AND ONE FOR THE ALUMINUM 102 00:05:41,729 --> 00:05:44,055 BECAUSE IF TECHNICIANS WERE TO USE THE SAME TOOL 103 00:05:44,057 --> 00:05:45,323 ON BOTH SURFACES, 104 00:05:45,325 --> 00:05:48,452 THE ALUMINUM COULD GET DAMAGED BY STEEL RESIDUE. 105 00:05:53,350 --> 00:05:56,143 ONCE THE REWORK TEAM HAS FINISHED REMOVING ANY DENTS 106 00:05:56,145 --> 00:05:57,544 OR HIGH SPOTS, 107 00:05:57,546 --> 00:05:59,338 THE BODY MOVES TO THE PAINT SHOP, 108 00:05:59,340 --> 00:06:01,540 WHERE A TEAM MEMBER DEGREASES IT. 109 00:06:06,473 --> 00:06:08,163 WHILE MUCH OF THE PAINT SHOP PROCESS 110 00:06:08,165 --> 00:06:10,366 IS AUTOMATED, AT THIS STATION, 111 00:06:10,368 --> 00:06:12,493 TECHNICIANS MANUALLY BRUSH A SEALANT 112 00:06:12,495 --> 00:06:14,821 INTO CERTAIN SPECIFIED JOINTS AND APERTURES 113 00:06:14,823 --> 00:06:18,291 ON THE BODY THAT ARE HARD FOR THE ROBOTS TO REACH. 114 00:06:23,249 --> 00:06:25,248 AS THE BODY ENTERS THIS STATION, 115 00:06:25,250 --> 00:06:27,443 A CAMERA TAKES A PICTURE TO CONFIRM THE CAR 116 00:06:27,445 --> 00:06:30,546 MODEL AND ESTABLISH A LOCATION REFERENCE POINT. 117 00:06:34,911 --> 00:06:37,570 NOW THAT THE ROBOTS KNOW WHICH KIND OF CAR IT IS 118 00:06:37,572 --> 00:06:39,464 AND WHERE EXACTLY IT'S LOCATED, 119 00:06:39,466 --> 00:06:42,400 THEY CAN GO TO WORK. 120 00:06:42,402 --> 00:06:43,727 THEY USE THE SAME SEALANT 121 00:06:43,729 --> 00:06:46,063 AS THE TECHNICIANS AT THE PREVIOUS STATION, 122 00:06:46,065 --> 00:06:48,523 APPLYING A THICK BEAD OVER EVERY JOINT 123 00:06:48,525 --> 00:06:50,993 TO ENSURE NO WATER CAN PENETRATE. 124 00:06:56,184 --> 00:06:59,251 BELL-SHAPED NOZZLES SPRAY PRIMER. 125 00:06:59,253 --> 00:07:01,411 THE PAINT CONTAINS A POSITIVE CHARGE 126 00:07:01,413 --> 00:07:04,073 TO ADHERE TO THE NEGATIVELY CHARGED ELECTROCOAT 127 00:07:04,075 --> 00:07:07,936 TO ENSURE MAXIMUM COVERAGE AND MINIMAL WASTE. 128 00:07:07,938 --> 00:07:10,204 JAGUAR USES A PRIMER PIGMENTED 129 00:07:10,206 --> 00:07:12,532 TO MATCH THE FINAL COLOR OF THE CAR. 130 00:07:15,070 --> 00:07:18,496 PAINT EXPERTS PRIME THE INTERIOR MANUALLY. 131 00:07:18,498 --> 00:07:22,693 THEN THE CAR MOVES TO THE BASE-COAT ROBOT BOOTH. 132 00:07:22,695 --> 00:07:25,621 HERE, ROBOTS EQUIPPED WITH MULTIPLE NOZZLE HEADS 133 00:07:25,623 --> 00:07:28,749 COVER THE CAR WITH ITS BASE COAT. 134 00:07:28,751 --> 00:07:32,286 INTERESTINGLY, WHITE IS ONE OF THE MOST POPULAR CHOICES. 135 00:07:32,288 --> 00:07:34,647 HOWEVER, THE ROBOTS CAN PURGE A COLOR 136 00:07:34,649 --> 00:07:36,483 IN JUST 8 SECONDS. 137 00:07:39,313 --> 00:07:42,172 THAT MEANS AS DIFFERENT COLOR CARS COME THROUGH, 138 00:07:42,174 --> 00:07:44,767 THERE'S NO NEED TO PAUSE BETWEEN COLORS. 139 00:07:47,237 --> 00:07:49,063 AFTER THE BASE COAT GOES ON, 140 00:07:49,065 --> 00:07:50,597 THE CAR HEADS FOR A STINT 141 00:07:50,599 --> 00:07:52,333 IN THE OVEN TO CURE THE PAINT 142 00:07:52,335 --> 00:07:55,394 BEFORE RECEIVING A PROTECTIVE CLEAR COAT. 143 00:07:55,396 --> 00:07:58,790 WHILE IN THE OVEN, THE SPECIAL NOISE-REDUCING PADS AND BAFFLES 144 00:07:58,792 --> 00:08:01,918 POSITIONED BETWEEN THE INNER AND OUTER SKIN OF THE CAR 145 00:08:01,920 --> 00:08:04,120 WILL EXPAND IN PLACE. 146 00:08:07,551 --> 00:08:08,750 IN THE INSPECTION AREA, 147 00:08:08,752 --> 00:08:11,278 THE CAR MOVES THROUGH DIFFERENT STATIONS 148 00:08:11,280 --> 00:08:13,012 WHERE INSPECTORS FOCUS ON EXAMINING 149 00:08:13,014 --> 00:08:15,206 A PARTICULAR PART OF THE CAR. 150 00:08:15,208 --> 00:08:17,835 TECHNICIANS QUICKLY CORRECT ANY IMPERFECTIONS. 151 00:08:30,234 --> 00:08:33,627 Narrator: THIS VIEW OF JAGUAR LAND ROVER'S NEW INGENIUM ENGINE 152 00:08:33,629 --> 00:08:36,422 IS ON DISPLAY IN THE POWERTRAIN WAY ATRIUM 153 00:08:36,424 --> 00:08:39,292 OF THE COMPANY'S ENGINE MANUFACTURING CENTER. 154 00:08:39,294 --> 00:08:41,585 IT WAS CREATED FOR THE QUEEN'S CEREMONIAL 155 00:08:41,587 --> 00:08:44,581 OPENING OF THE FACILITY IN 2014. 156 00:08:46,985 --> 00:08:48,844 AN AUTOMATED SYSTEM LOADS THE ROUGH 157 00:08:48,846 --> 00:08:51,780 FORGING OF THE STEEL CRANK INTO A MILLING MACHINE 158 00:08:51,782 --> 00:08:56,702 THAT WILL COMPLETE THE FIRST OF TWO OPERATIONS. 159 00:08:56,704 --> 00:08:59,571 THIS MACHINE USES HIGH-SPEED CARBIDE-TIPPED TOOLS 160 00:08:59,573 --> 00:09:04,160 TO CUT THE CRANK DOWN TO ITS APPROXIMATE SHAPE. 161 00:09:04,162 --> 00:09:05,794 THIS MEANS THE MACHINE REMOVES 162 00:09:05,796 --> 00:09:09,323 METAL BUT DOESN'T FINISH THE SURFACES. 163 00:09:09,325 --> 00:09:12,786 THIS PROCESS IS HIGH-PRECISION WORK. 164 00:09:12,788 --> 00:09:14,320 THE MACHINE BRINGS THE SURFACES 165 00:09:14,322 --> 00:09:19,284 TO WITHIN 250 MICRONS OF THEIR FINISHED PARAMETERS. 166 00:09:19,286 --> 00:09:21,411 A SET OF CLAMPS REPOSITION THEMSELVES 167 00:09:21,413 --> 00:09:23,680 WITH THE MILLING TOOLS TO PREVENT THE CRANK 168 00:09:23,682 --> 00:09:26,875 FROM BOWING UNDER PRESSURE FROM THE LOAD BEING APPLIED. 169 00:09:34,102 --> 00:09:36,101 A GANTRY LOADER TRANSFERS THE CRANK 170 00:09:36,103 --> 00:09:38,162 TO THIS FINISHING STATION. 171 00:09:38,164 --> 00:09:41,358 HERE, MULTIPLE ARMS EQUIPPED WITH FINE EMERY PAPER 172 00:09:41,360 --> 00:09:44,894 CLOSE AROUND THE CRANK AND BEGIN POLISHING. 173 00:09:44,896 --> 00:09:48,890 THE MACHINE SPINS THE CRANK UP TO 100 RPM 174 00:09:48,892 --> 00:09:53,779 WHILE SIMULTANEOUSLY CREATING 180 OSCILLATIONS PER SECOND. 175 00:09:53,781 --> 00:09:55,847 HYDRAULIC OIL FLOWS CONTINUOUSLY, 176 00:09:55,849 --> 00:09:57,708 CLEANING GRIT FROM THE PAPER 177 00:09:57,710 --> 00:10:00,211 TO ENSURE THE PROCESS RUNS SMOOTHLY. 178 00:10:02,240 --> 00:10:04,106 A TECHNICIAN USES A LIFT ASSIST 179 00:10:04,108 --> 00:10:07,534 TO LOAD THE CRANK INTO THE CRANKCASE. 180 00:10:07,536 --> 00:10:10,530 THIS STATION IS IN THE FIRST OF 17 ZONES 181 00:10:10,532 --> 00:10:12,465 IN THE DIESEL ASSEMBLY HALL. 182 00:10:15,261 --> 00:10:17,129 TWO ROBOTS WORK IN UNISON. 183 00:10:17,131 --> 00:10:19,323 WHILE ON LIFTS AND LOADS THE ENGINE BLOCKS 184 00:10:19,325 --> 00:10:20,791 INTO A LOCATOR DEVICE, 185 00:10:20,793 --> 00:10:24,420 THE SECOND BRINGS PISTONS INTO STUFFING POSITION. 186 00:10:24,422 --> 00:10:27,148 THE LOADING DEVICE THEN GRIPS THE TOP OF THE PISTON 187 00:10:27,150 --> 00:10:30,143 AND COMPRESSES ITS PISTON RINGS BEFORE INSERTING. 188 00:10:33,147 --> 00:10:35,473 THERE ARE TWO PISTON LOAD STATIONS. 189 00:10:35,475 --> 00:10:37,675 EACH ONE IS RESPONSIBLE FOR INSTALLING TWO 190 00:10:37,677 --> 00:10:39,836 OF THE ENGINE'S FOUR PISTONS. 191 00:10:43,967 --> 00:10:45,833 A TECHNICIAN BRINGS THE CYLINDER HEAD 192 00:10:45,835 --> 00:10:48,428 TO THE ENGINE BLOCK. 193 00:10:48,430 --> 00:10:50,030 WITH THE HELP OF LOCATOR PINS, 194 00:10:50,032 --> 00:10:52,725 HE ALIGNS AND LOWERS IT INTO PLACE. 195 00:10:56,455 --> 00:10:58,122 TEAM MEMBERS LOAD THE CAM CARRIER 196 00:10:58,124 --> 00:11:00,049 SUBASSEMBLY INTO POSITION. 197 00:11:00,051 --> 00:11:01,450 LIKE OTHER COMPONENTS, 198 00:11:01,452 --> 00:11:04,979 THIS CAN DIFFER FROM ENGINE TO ENGINE. 199 00:11:04,981 --> 00:11:07,073 THIS PRODUCTION LINE IS SO FLEXIBLE 200 00:11:07,075 --> 00:11:09,509 THAT IT CAN PRODUCE UP TO 28 DIFFERENT DERIVATIVES 201 00:11:09,511 --> 00:11:11,603 OF THE INGENIUM AT THE SAME TIME. 202 00:11:16,201 --> 00:11:18,935 A TECHNICIAN INSTALLS INJECTORS. 203 00:11:18,937 --> 00:11:23,331 DIFFERENT ENGINE DERIVATIVES CAN REQUIRE DIFFERENT INJECTORS. 204 00:11:23,333 --> 00:11:25,593 AN AUTOMATED SYSTEM ENSURES HE IS POSITIONING 205 00:11:25,595 --> 00:11:28,387 THE CORRECT INJECTORS IN THE RIGHT ENGINE. 206 00:11:28,389 --> 00:11:30,389 HE SCANS THEIR TWO DIMENSIONAL CODES 207 00:11:30,391 --> 00:11:33,083 TO VERIFY THE INSTALLATION. 208 00:11:33,085 --> 00:11:37,413 A CAMERA WILL VERIFY THE ASSEMBLY TO TRIPLE-CHECK. 209 00:11:37,415 --> 00:11:40,408 AT THE NEXT STATION, A TEAM MEMBER INSTALLS THE CLAMPS 210 00:11:40,410 --> 00:11:42,477 THAT HOLD THE INJECTORS IN PLACE. 211 00:11:44,540 --> 00:11:45,939 HE RUNS DOWN THE BOLTS 212 00:11:45,941 --> 00:11:47,874 WITH A DIGITALLY CONTROLLED DRIVER 213 00:11:47,876 --> 00:11:49,568 THAT MONITORS THE ANGLE TRAVELED 214 00:11:49,570 --> 00:11:51,503 BY THE FASTENER AND THE TORQUE, 215 00:11:51,505 --> 00:11:54,198 WHICH MUST FALL WITHIN A SPECIFIED WINDOW. 216 00:12:00,231 --> 00:12:02,423 A TECHNICIAN POSITIONS A GUIDE PIN, 217 00:12:02,425 --> 00:12:06,318 WHICH HELPS HIM LOCATE THE HIGH-PRESSURE FUEL RAIL. 218 00:12:06,320 --> 00:12:09,581 THE TORQUE SEQUENCE IS CRUCIAL HERE. 219 00:12:09,583 --> 00:12:11,850 AFTER RUNNING DOWN EACH OF THE TWO BOLTS, 220 00:12:11,852 --> 00:12:16,179 THE TOOL AUTOMATICALLY BACKS THEM OFF A QUARTER TURN. 221 00:12:16,181 --> 00:12:18,841 THIS IS BECAUSE THEY CAN'T BE TIGHTENED DOWN FULLY 222 00:12:18,843 --> 00:12:21,569 UNTIL THE HIGH-PRESSURE PIPES ARE INSTALLED. 223 00:12:24,741 --> 00:12:26,065 AT THE NEXT STATION, 224 00:12:26,067 --> 00:12:29,126 A TEAM MEMBER POSITIONS THE FOUR HIGH-PRESSURE PIPES 225 00:12:29,128 --> 00:12:32,530 AND FINGER-TIGHTENS THEIR FASTENERS. 226 00:12:32,532 --> 00:12:37,552 THE PIPES CARRY FUEL FROM THE RAIL TO THE INJECTORS. 227 00:12:37,554 --> 00:12:39,087 IN SOME OF THE DIESEL ENGINES, 228 00:12:39,089 --> 00:12:42,816 THE PRESSURE CAN BE AS HIGH AS 26 POUNDS PER SQUARE INCH. 229 00:12:47,814 --> 00:12:50,074 BECAUSE THE USUAL TORQUE TOOLS CAN'T ACCESS 230 00:12:50,076 --> 00:12:51,609 THE NUTS ON THE PIPES, 231 00:12:51,611 --> 00:12:53,343 A TECHNICIAN USES AN OPEN WRENCH 232 00:12:53,345 --> 00:12:57,039 TO TIGHTEN THE FASTENERS TO THE REQUIRED PARAMETERS. 233 00:12:57,041 --> 00:13:00,434 THESE TOOLS USE BLUETOOTH TECHNOLOGY TO COMMUNICATE 234 00:13:00,436 --> 00:13:02,462 WITH THE PRODUCTION CONTROL SYSTEM. 235 00:13:04,766 --> 00:13:06,825 HERE, NEARING COMPLETION, 236 00:13:06,827 --> 00:13:09,427 THE ENGINE HAS BEEN EQUIPPED WITH ITS WIRING HARNESS 237 00:13:09,429 --> 00:13:11,788 AND HEADS FOR THE INLINE TESTING STATION 238 00:13:11,790 --> 00:13:13,724 ON A RAIL TRANSPORT SYSTEM. 239 00:13:18,055 --> 00:13:20,380 THE TESTING STATION CAN ACCOMMODATE THREE ENGINES 240 00:13:20,382 --> 00:13:23,108 AT A TIME. 241 00:13:23,110 --> 00:13:24,911 WHILE THE SYSTEM TESTS ONE ENGINE, 242 00:13:24,913 --> 00:13:28,473 A TECHNICIAN PREPARES A SECOND AND FINISHES OFF A THIRD. 243 00:13:31,403 --> 00:13:33,002 THE SYSTEM PLUGS AN ELECTRIC MOTOR 244 00:13:33,004 --> 00:13:34,403 INTO THE TRANSMISSION 245 00:13:34,405 --> 00:13:37,265 AND SPINS THE ENGINE UP TO 3,000 RPM 246 00:13:37,267 --> 00:13:38,992 WHILE CHECKING DOZENS OF PARAMETERS 247 00:13:38,994 --> 00:13:41,662 IN JUST 90 SECONDS. 248 00:13:44,659 --> 00:13:46,325 ONCE THE ENGINE MANUFACTURING 249 00:13:46,327 --> 00:13:48,485 CENTER HAS FINISHED BUILDING AN ENGINE, 250 00:13:48,487 --> 00:13:51,214 IT COMES HERE TO THE POWERTRAIN ASSEMBLY LINE 251 00:13:51,216 --> 00:13:53,682 WHERE TEAM MEMBERS LOWER IT ONTO A FRONT AXLE 252 00:13:53,684 --> 00:13:55,643 AND FASTEN IT IN PLACE. 253 00:13:57,881 --> 00:14:00,806 FOR THE REAR-WHEEL-DRIVE XF, 254 00:14:00,808 --> 00:14:03,368 THEY INSTALL THIS 2-LITER FOUR-CYLINDER ENGINE 255 00:14:03,370 --> 00:14:05,504 IN A NORTH-SOUTH ORIENTATION. 256 00:14:08,700 --> 00:14:11,426 TECHNICIANS THEN POSITION AND ATTACH THE COOLANT PACK, 257 00:14:11,428 --> 00:14:14,896 INCLUDING THE MAIN RADIATOR. 258 00:14:14,898 --> 00:14:16,690 THE LIGHTWEIGHT COMPONENT MAKES GOOD USE 259 00:14:16,692 --> 00:14:18,959 OF ALUMINUM'S THERMAL CONDUCTION PROPERTIES 260 00:14:18,961 --> 00:14:20,853 TO HELP REMOVE HEAT FROM THE ENGINE 261 00:14:20,855 --> 00:14:22,955 AS EFFICIENTLY AS POSSIBLE. 262 00:14:32,797 --> 00:14:34,722 Narrator: WHETHER YOU'RE LOOKING UNDER THE HOOD 263 00:14:34,724 --> 00:14:37,190 OR SITTING INSIDE ITS LUXURIOUS COCKPIT, 264 00:14:37,192 --> 00:14:42,180 THE JAGUAR XF PRESENTS SLEEK FINISHED LINES AND SURFACES. 265 00:14:42,182 --> 00:14:44,849 BUT GETTING IT TO THIS POINT REQUIRES A PRECISE 266 00:14:44,851 --> 00:14:46,776 AND EFFICIENT PRODUCTION LINE. 267 00:14:48,813 --> 00:14:50,806 HERE ON THE GENERAL ASSEMBLY LINE, 268 00:14:50,808 --> 00:14:53,541 TEAM MEMBERS BRING THE WIRING HARNESS TO THE CAR 269 00:14:53,543 --> 00:14:56,704 WITH THE HELP OF A SPECIALIZED LIFT-ASSIST DEVICE. 270 00:14:59,533 --> 00:15:02,693 THE HARNESS HAS BEEN HEATED TO HELP MAKE IT MALLEABLE ENOUGH 271 00:15:02,695 --> 00:15:04,362 TO TUCK EASILY INTO THE CORNERS 272 00:15:04,364 --> 00:15:07,556 AND CREVICES OF THE CAR'S INTERIOR. 273 00:15:07,558 --> 00:15:10,760 THE FOUR-MAN TEAM HAS JUST 190 SECONDS 274 00:15:10,762 --> 00:15:14,622 TO FULLY INSTALL THE HARNESS. 275 00:15:14,624 --> 00:15:16,683 EACH HARNESS IS COMPLETELY CUSTOMIZED 276 00:15:16,685 --> 00:15:18,285 TO MEET THE PRECISE PARAMETERS 277 00:15:18,287 --> 00:15:20,245 REQUESTED BY THE CLIENT. 278 00:15:25,978 --> 00:15:27,503 ONE OF THE MANY FEATURES CUSTOMERS 279 00:15:27,505 --> 00:15:31,432 CAN CHOOSE IS A PANORAMIC GLASS ROOF. 280 00:15:31,434 --> 00:15:33,701 HERE, A ROBOT BRINGS THE GLASS 281 00:15:33,703 --> 00:15:37,196 TO A DEVICE WHICH CENTERS IT PERFECTLY. 282 00:15:37,198 --> 00:15:39,557 THIS IS CRUCIAL TO ENSURING THE INSTALLATION 283 00:15:39,559 --> 00:15:40,825 WILL BE FLAWLESS. 284 00:15:44,523 --> 00:15:47,457 A ROBOT THEN TRANSFERS THE GLASS TO A MACHINE 285 00:15:47,459 --> 00:15:50,251 WHICH APPLIES A THICK BEAD OF POLYURETHANE ADHESIVE 286 00:15:50,253 --> 00:15:54,148 DESIGNED TO BOND DISSIMILAR MATERIALS. 287 00:15:54,150 --> 00:15:58,077 HERE, IT MUST BOND GLASS TO METAL. 288 00:15:58,079 --> 00:16:01,872 TEAM MEMBERS GUIDE AN ASSISTER DOWN INTO PLACE. 289 00:16:01,874 --> 00:16:03,407 LOCATION PINS ON THE GLASS 290 00:16:03,409 --> 00:16:05,601 FIT INTO HOLES IN THE ROOF FRAME, 291 00:16:05,603 --> 00:16:08,896 ENSURING PRECISE INSTALLATION. 292 00:16:08,898 --> 00:16:12,225 THE ASSISTER APPLIES PRECISELY DESIGNATED AMOUNT OF FORCE 293 00:16:12,227 --> 00:16:13,894 TO FIX IT IN PLACE. 294 00:16:18,025 --> 00:16:20,091 A THREE-PART JIG HELPS THE TECHNICIAN 295 00:16:20,093 --> 00:16:22,485 INSTALL ALL OF THE NECESSARY BADGES, 296 00:16:22,487 --> 00:16:24,713 INCLUDING THE FAMOUS JAGUAR SYMBOL 297 00:16:24,715 --> 00:16:26,582 AND THE LEGENDARY NAME. 298 00:16:28,978 --> 00:16:32,646 THE XF's BATTERY SITS IN A WELL UNDER THE TRUNK. 299 00:16:32,648 --> 00:16:33,840 IT'S POSITIONED BACK HERE 300 00:16:33,842 --> 00:16:36,309 TO IMPROVE THE CAR'S WEIGHT DISTRIBUTION. 301 00:16:38,504 --> 00:16:39,771 CAREFULLY DISTRIBUTING THE WEIGHT 302 00:16:39,773 --> 00:16:41,131 THROUGHOUT A CAR HELPS 303 00:16:41,133 --> 00:16:43,400 TO IMPROVE ITS DYNAMIC HANDLING. 304 00:16:47,798 --> 00:16:50,256 WITH THE HELP OF A SPECIALIZED LIFT ASSIST, 305 00:16:50,258 --> 00:16:53,919 TEAM MEMBERS INSTALL A DASHBOARD. 306 00:16:53,921 --> 00:16:56,788 CONTAINING THE INSTRUMENT PANELS AND THE ENTERTAINMENT INTERFACE, 307 00:16:56,790 --> 00:16:59,082 THIS ELEMENT OF THE CAR'S INTERIOR 308 00:16:59,084 --> 00:17:02,512 HAS BEEN UPHOLSTERED TO THE CLIENT'S SPECS BY A SUPPLIER. 309 00:17:05,742 --> 00:17:07,675 TECHNICIANS POSITION THE WINDSHIELD 310 00:17:07,677 --> 00:17:09,343 FOLLOWING A SIMILAR PROCEDURE 311 00:17:09,345 --> 00:17:13,732 TO THE INSTALLATION OF THE PANORAMIC ROOF. 312 00:17:13,734 --> 00:17:15,000 THE RAISED HOOD ENSURES 313 00:17:15,002 --> 00:17:17,002 THAT TEAM MEMBERS CAN PLACE THE GLASS 314 00:17:17,004 --> 00:17:19,162 WITHOUT DRAGGING THE BEAD OF ADHESIVE 315 00:17:19,164 --> 00:17:21,698 OVER THE FRAME AS THEY DO SO. 316 00:17:21,700 --> 00:17:25,027 THEY THEN TAP THE GLASS FIRMLY IN PLACE. 317 00:17:29,025 --> 00:17:30,416 ON THE POWERTRAIN LINE, 318 00:17:30,418 --> 00:17:32,418 A TECHNICIAN LOWERS THE REAR AXLE, 319 00:17:32,420 --> 00:17:36,448 SUBFRAME, AND PROP SHAFT ONTO A VERY COMPLEX JIG, 320 00:17:36,450 --> 00:17:39,442 WHICH WILL EVENTUALLY HOLD ALL THE ELEMENTS OF THE POWERTRAIN 321 00:17:39,444 --> 00:17:41,678 DURING THE SUBASSEMBLY PROCESS. 322 00:17:46,043 --> 00:17:48,502 AS THE JIG ADVANCES DOWN THE LINE, 323 00:17:48,504 --> 00:17:50,562 IT PAUSES WHEN IT MEETS A CONVEYOR SYSTEM 324 00:17:50,564 --> 00:17:52,798 CARRYING THE ENGINE. 325 00:17:52,800 --> 00:17:54,658 THE AUTOMATED SYSTEM LOADS THE ENGINE 326 00:17:54,660 --> 00:17:57,928 ONTO THE POWERTRAIN JIG. 327 00:17:57,930 --> 00:18:00,256 THE JIG THEN PROCEEDS TO THE NEXT STATION, 328 00:18:00,258 --> 00:18:02,751 WHERE IT WILL MARRY WITH THE XF BODY. 329 00:18:08,016 --> 00:18:11,275 THE MARRIAGE IS ALSO FULLY AUTOMATED. 330 00:18:11,277 --> 00:18:14,012 THE POWERTRAIN SLIDES IN UNDERNEATH THE BODY, 331 00:18:14,014 --> 00:18:17,141 WHICH IS SUSPENDED FROM AN OVERHEAD TRACK. 332 00:18:17,143 --> 00:18:20,835 PRECISION LASERS ALIGN THE TWO ASSEMBLIES PERFECTLY. 333 00:18:20,837 --> 00:18:24,097 SENSORS KEEP TRACK OF THE OPERATION'S PROGRESS. 334 00:18:24,099 --> 00:18:25,832 AND IF ANYTHING IS OUT OF ALIGNMENT, 335 00:18:25,834 --> 00:18:27,694 THEY WILL HALT THE PROCEDURE. 336 00:18:31,099 --> 00:18:34,225 SIX ROBOTS SEND DRIVERS UP THROUGH THE SUBFRAME 337 00:18:34,227 --> 00:18:38,021 ASSEMBLY AND ATTACH IT SECURELY TO THE BODY. 338 00:18:38,023 --> 00:18:40,982 IF THE ROBOTS FAIL TO ACHIEVE THE CORRECT TORQUE, 339 00:18:40,984 --> 00:18:42,651 EVERYTHING WILL AUTOMATICALLY STOP 340 00:18:42,653 --> 00:18:44,645 UNTIL THE PROBLEM IS CORRECTED. 341 00:18:49,110 --> 00:18:50,976 WHILE THE CAR IS STILL ELEVATED, 342 00:18:50,978 --> 00:18:52,970 TEAM MEMBERS PERFORM THE NEXT OPERATION 343 00:18:52,972 --> 00:18:56,632 OF INSTALLING THE FINAL SILENCERS AND TAILPIPES. 344 00:18:58,336 --> 00:19:00,661 THERE ARE 16 DIFFERENT POSSIBLE DERIVATIVES 345 00:19:00,663 --> 00:19:02,130 FOR THE EXHAUST SYSTEM, 346 00:19:02,132 --> 00:19:05,992 DEPENDING ON THE TYPE OF ENGINE CHOSEN BY THE CUSTOMER. 347 00:19:05,994 --> 00:19:08,261 THE TECHNICIANS USE THE JIG ATTACHMENT 348 00:19:08,263 --> 00:19:12,190 TO ENSURE THE TAILPIPES ARE PERFECTLY SITUATED. 349 00:19:12,192 --> 00:19:14,484 THIS IS NOT ONLY A MATTER OF AESTHETIC BALANCE, 350 00:19:14,486 --> 00:19:17,412 BUT ALSO OF PRACTICALITY. 351 00:19:17,414 --> 00:19:19,681 THE TAILPIPES MUST BE CORRECTLY POSITIONED 352 00:19:19,683 --> 00:19:21,776 FOR THE REAR BUMPER TO FIT OVER THEM. 353 00:19:28,869 --> 00:19:31,336 THE BUMPERS ARE MADE OF A PLASTIC COMPOSITE, 354 00:19:31,338 --> 00:19:33,563 A LIGHTWEIGHT MATERIAL THAT CAN BE REPLACED 355 00:19:33,565 --> 00:19:35,364 INEXPENSIVELY IN CASE OF MINOR 356 00:19:35,366 --> 00:19:37,459 DAMAGE DUE TO A FENDER BENDER. 357 00:19:42,091 --> 00:19:44,758 TECHNICIANS EASILY INSTALL THESE ELEMENTS OF THE BODY 358 00:19:44,760 --> 00:19:48,320 BY SNAPPING THEM INTO PLACE WITH A FEW WELL-PLACED TAPS. 359 00:19:51,183 --> 00:19:54,643 CUSTOMERS CAN CHOOSE A RIGHT- OR LEFT-DRIVE VEHICLE. 360 00:19:54,645 --> 00:19:56,578 HERE, A TEAM MEMBER INSTALLS A STEERING 361 00:19:56,580 --> 00:19:58,840 WHEEL ON THE RIGHT. 362 00:19:58,842 --> 00:20:01,701 A PURPOSE-BUILT JIG HELPS HIM GUIDE IN THE FASTENER. 363 00:20:01,703 --> 00:20:04,337 AND HE FINISHES BY WIRING IN THE AIRBAG. 364 00:20:09,069 --> 00:20:12,328 AN AUTOMATED DELIVERY SYSTEM SEQUENCES AND MATCHES TIRES 365 00:20:12,330 --> 00:20:15,190 TO THEIR SPECIFIED CARS. 366 00:20:15,192 --> 00:20:18,719 A SPECIALIZED DRIVER APPLIES 81 FOOT-POUNDS OF TORQUE 367 00:20:18,721 --> 00:20:22,114 TO EACH OF THE LUGS SIMULTANEOUSLY. 368 00:20:22,116 --> 00:20:23,683 THE COMPLETED CARS UNDERGO 369 00:20:23,685 --> 00:20:26,177 AN INTENSIVE SERIES OF QUALITY-CONTROL 370 00:20:26,179 --> 00:20:27,478 INSPECTIONS AND TESTS 371 00:20:27,480 --> 00:20:31,074 BEFORE JAGUAR CONSIDERS THEM FINISHED. 372 00:20:31,076 --> 00:20:35,136 THE 2007 XF MODERNIZED THE JAGUAR IMAGE. 373 00:20:35,138 --> 00:20:39,165 AND THE ALL NEW XF BRINGS THAT MODERNIZATION A STEP FURTHER. 374 00:20:39,167 --> 00:20:42,895 THE 75-PERCENT ALUMINUM UNIBODY MAKES IT BOTH LIGHTER 375 00:20:42,897 --> 00:20:46,432 AND MORE RIGID THAN ITS PREDECESSOR. 376 00:20:46,434 --> 00:20:49,093 UNDER THE HOOD, THE INNOVATIVE INGENIUM ENGINE 377 00:20:49,095 --> 00:20:51,420 MAKES IT SIMULTANEOUSLY FASTER, 378 00:20:51,422 --> 00:20:53,889 MORE POWERFUL AND MORE EFFICIENT. 379 00:20:53,891 --> 00:20:57,318 INSIDE, LUXURY IS EVERYWHERE ON DISPLAY,FROM 380 00:20:57,320 --> 00:20:58,719 THE VISUALLY DRAMATIC START-UP 381 00:20:58,721 --> 00:21:02,715 SEQUENCE FEATURING TOUCH-SCREEN COMMAND OPTIONS 382 00:21:02,717 --> 00:21:04,976 TO THE FINELY CRAFTED LEATHER UPHOLSTERY OF 383 00:21:04,978 --> 00:21:08,638 THE STEERING WHEEL, DASHBOARD, AND SEATS. 384 00:21:08,640 --> 00:21:12,401 THE XF IS BUILT TO SUPERIOR PERFORMANCE STANDARDS. 385 00:21:12,403 --> 00:21:15,863 CUSTOMERS CAN OPT FOR ALL-WHEEL DRIVE WITH INTELLIGENT DRIVELINE 386 00:21:15,865 --> 00:21:19,066 DYNAMICS, WHICH DEPLOYS A SPECIALIZED SOFTWARE 387 00:21:19,068 --> 00:21:20,660 TO ANALYZE DRIVING CONDITIONS 388 00:21:20,662 --> 00:21:24,255 AND OPTIMIZE TRACTION AND BALANCE. 389 00:21:24,257 --> 00:21:27,057 AS A RESULT, THIS JAGUAR IS FAST, 390 00:21:27,059 --> 00:21:29,953 QUIET, AND SUREFOOTED AT ALL TIMES, 391 00:21:29,955 --> 00:21:32,381 JUST LIKE ITS NAMESAKE. 30871

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